1st Groups Assignment

Extrusion.
1. Calculate the force required in direct extrusion of 1100-O Aluminum
from a diameter of 6 in. to 2 in. Assume that the redundant work is
30% of the ideal work of deformation, and the friction work is 25%
of the total work of deformation.

Cutting
2. Taking carbide as an example and using Eq. (8.30), determine how
much the feed should be changed in order to keep the mean
temperature constant when the cutting speed is tripled.
Answer of Groups Assignment
 Additional Assignment
1. A flat-rolling operation is being carried out where h0 = 0.2 in., hf = 0.15
in., w0 = 10 in., R = 8 in., μ = 0.25, and the average flow stress of the
material is 40,000 psi. Estimate the roll force and the torque. Include
the effects of roll flattening.

2. A planned extrusion operation involves steel at 800oC, with an initial

diameter of 100 mm and a final diameter of 20 mm. Two presses, one
with a capacity of 20 MN and the other of 10 MN, are available for this
operation. Obviously, the larger press requires greater care and more
expensive tooling. Is the smaller press sufficient for this operation? If
not, what recommendations would you make to allow the use of the
smaller press?
2 nd Exercise of Turning
1. An 8-in-diameter stainless-steel bar is being turned on a lathe at 600
rpm and at a depth of cut, d = 0.1 in. If the power of the motor is 5 hp
and has a mechanical efficiency of 80%, what is the maximum feed that
you can have at a spindle speed of 500 rpm before the motor stalls?

2. A 150-mm-long, 75-mm-diameter titanium alloy rod is being reduced

in diameter to 65 mm by turning on a lathe in one pass. The spindle
rotates at 400 rpm and the tool is traveling at an axial velocity of 200
mm/min Calculate the cutting speed, material removal rate, time of
cut, power required, and the cutting force.